Method of producing preform and method of molding composite material

Abstract

A method of producing a preform includes: laminating first prepreg tapes with at least one interval in a width direction of the first prepreg tapes using an automated fiber placement apparatus configured to allow disposing desired prepreg tapes, supplied from bobbins, in a width direction of the desired prepreg tapes, and feeding out the disposed desired prepreg tapes in a length direction of the disposed desired prepreg tapes; and laminating at least one second prepreg tape in the at least one interval between the laminated first prepreg tapes, using the automated fiber placement apparatus. The preform is a material for a fiber reinforced plastic.

What is claimed is: 
     
         1 . A method of producing a preform, which is a material for a fiber reinforced plastic, comprising:
 laminating first prepreg tapes with at least one interval in a width direction of the first prepreg tapes using an automated fiber placement apparatus, having at least one roller and bobbins, configured to allow disposing desired prepreg tapes, supplied from the bobbins, in a width direction of the desired prepreg tapes, and feeding out the disposed desired prepreg tapes, in a length direction of the disposed desired prepreg tapes, using the at least one roller; and   laminating at least one second prepreg tape in the at least one interval between the laminated first prepreg tapes, using the automated fiber placement apparatus.   
     
     
         2 . The method of producing the preform according to  claim 1 ,
 wherein the automated fiber placement apparatus is configured to allow disposing the desired prepreg tapes with no gap in the width direction of the desired prepreg tapes, and feeding out the disposed desired prepreg tapes simultaneously,   the at least one roller is configured to apply pressure to the disposed desired prepreg tapes, and   the at least one interval is formed between the first prepreg tapes by detaching a part of the desired prepreg tapes from the automated fiber placement apparatus, or stopping feeding out the part of the desired prepreg tapes.   
     
     
         3 . The method of producing the preform according to  claim 1 ,
 wherein the at least one second prepreg tape includes second prepreg tapes,   a first number of the first prepreg tapes is same as a second number of the second prepreg tapes,   the at least one interval of the first prepreg tapes includes first intervals,   the second prepreg tapes are laminated at second intervals in a width direction of the second prepreg tapes,   the second intervals are same as the first intervals,   the second prepreg tapes are laminated alternately with the first prepreg tapes,   the automated fiber placement apparatus has a lamination head,   the lamination head is reciprocated by reversing the lamination head,   the first prepreg tapes are laminated in an outward path of the lamination head,   the second prepreg tapes are laminated in a return path of the lamination head after reversing the lamination head, and   a line, for defining a movement path of the lamination head, used for creating a control program for the lamination head is made common to the outward path and the return path of the lamination head.   
     
     
         4 . The method of producing the preform according to  claim 1 ,
 wherein the automated fiber placement apparatus is configured to allow disposing the desired prepreg tapes and feeding out the disposed desired prepreg tapes while changing widths of the desired prepreg tapes,   the first prepreg tapes are laminated with the at least one interval having a changing width while changing first widths of the first prepreg tapes, and   the at least one second prepreg tape of which second width changes according to the at least one interval having the changing width is laminated in the at least one interval having the changing width.   
     
     
         5 . A method of molding a composite material comprising:
 molding the fiber reinforced plastic as the composite material, using the preform produced by the method according to  claim 1 .   
     
     
         6 . The method of producing the preform according to  claim 2 ,
 wherein the at least one second prepreg tape includes second prepreg tapes,   a first number of the first prepreg tapes is same as a second number of the second prepreg tapes,   the at least one interval of the first prepreg tapes includes first intervals,   the second prepreg tapes are laminated at second intervals in a width direction of the second prepreg tapes,   the second intervals are same as the first intervals,   the second prepreg tapes are laminated alternately with the first prepreg tapes,   the automated fiber placement apparatus has a lamination head,   the lamination head is reciprocated by reversing the lamination head,   the first prepreg tapes are laminated in an outward path of the lamination head,   the second prepreg tapes are laminated in a return path of the lamination head after reversing the lamination head, and   a line, for defining a movement path of the lamination head, used for creating a control program for the lamination head is made common to the outward path and the return path of the lamination head.   
     
     
         7 . The method of producing the preform according to  claim 2 ,
 wherein the automated fiber placement apparatus is configured to allow disposing the desired prepreg tapes and feeding out the disposed desired prepreg tapes while changing widths of the desired prepreg tapes,   the first prepreg tapes are laminated with the at least one interval having a changing width while changing first widths of the first prepreg tapes, and   the at least one second prepreg tape of which second width changes according to the at least one interval having the changing width is laminated in the at least one interval having the changing width.   
     
     
         8 . The method of producing the preform according to  claim 3 ,
 wherein the automated fiber placement apparatus is configured to allow disposing the desired prepreg tapes and feeding out the disposed desired prepreg tapes while changing widths of the desired prepreg tapes,   the first prepreg tapes are laminated with the at least one interval having a changing width while changing first widths of the first prepreg tapes, and   the at least one second prepreg tape of which second width changes according to the at least one interval having the changing width is laminated in the at least one interval having the changing width.   
     
     
         9 . A method of molding a composite material comprising:
 molding the fiber reinforced plastic as the composite material, using the preform produced by the method according to  claim 2 .   
     
     
         10 . A method of molding a composite material comprising:
 molding the fiber reinforced plastic as the composite material, using the preform produced by the method according to  claim 3 .   
     
     
         11 . A method of molding a composite material comprising:
 molding the fiber reinforced plastic as the composite material, using the preform produced by the method according to  claim 4 .   
     
     
         12 . A method of molding a composite material comprising:
 molding the fiber reinforced plastic as the composite material, using the preform produced by the method according to  claim 6 .   
     
     
         13 . A method of molding a composite material comprising:
 molding the fiber reinforced plastic as the composite material, using the preform produced by the method according to  claim 7 .   
     
     
         14 . A method of molding a composite material comprising:
 molding the fiber reinforced plastic as the composite material, using the preform produced by the method according to  claim 8 .